Gear Shift Lever Boss Replacement Sauce!

I got a message from Jorge that he needed help with replacing the DT shift lever bosses on his Surly. I’ve never done gear shift bosses before so this is the perfect chance to make a fixture for doing so!

Come to find out Jorge was referred to me by Jared Jerome of Jerome Cycles in Los Angeles. Jared builds some of the sweetest city bikes you’ll ever see so it was an honor to be referred by Jared.

Jeorge came up to my place to deliver the victim and we had a nice chat. Turns out this guys got a ton of bikes. My kinda guy!

When it comes time to design and build a new fixture you don’t have to twist my arm. Hopped onto Solidworks (which I am JUST starting to get a handle on the very tip of that iceberg) and put my ideas down on pixles. Came up with this little guy.

Took the model over to Mastercam and blasted out some high speed tool paths!

Then since our 4 axis was busy, I stood the part up and drilled the holes. First with a normal length drill and then took it up to level obserd with the really long drill!

Whalah!!!

Now onto the real thing! Here are the mangeled bosses.

Fluxed and heated the old bosses came off nicely.

Then I soaked off the flux and filed the brass off. Now for the new fixture! Cleaned up the tube and bosses, refluxed and rebrazed!

It held great! The bosses are colinear and level! Exactly what we want!

I posted a few pics of this on Facebook and IG and got some interest in this fixture. So I plan to knock out a handful or so more of these in the near future. Probably the last week of July (2017) so if you’re interested, shoot me an email.

allan@varcocycles.com

$50 shipped in the USA (little extra for the rest of the planet)

So, as always, till next time, keep your frikin’ head on a swivel, turn your lights on day or night, wear a damn helmet and go have some fun! It’s summer!